Apparatus for manufacturing flat cable and method for manufacturing the same

ABSTRACT

In a manufacturing apparatus for flat cable adapted for allowing plural conductive wires arranged on the same plane to be put between a first insulating tape on which first peeling sheets are stuck at predetermined intervals and a second insulating tape on which second peeling sheets are stuck at predetermined intervals to stick the first insulating tape, the conductive wires and the second insulating tape in order recited, such an approach is employed to respectively adjust tensions applied to the first and second insulating tapes to thereby respectively independently change expansions/contractions of the first and second insulating tapes. Thus, it is possible to correct sticking errors of the first peeling sheets and the second peeling sheets.

TECHNICAL FIELD

This invention relates to an apparatus for manufacturing flat cable anda method for manufacturing the same used for internal wiring, etc. ofelectronic equipments or automotive vehicles.

BACKGROUND ART

Flat cables are of structure in which plural conductive wires arrangedon the same plane are put between two insulating tapes. Since such flatcables are flat and have bending ability, there are merits that it iseasy to carry out wiring work and/or wiring can be made also at narrowportion, etc. For this reason, flat cables are widely used for internalwiring, etc. of various home electric products (equipments),communication equipments, word processors, computers and automotivevehicles.

Meanwhile, in manufacturing such flat cable, there is used amanufacturing apparatus as shown in FIG. 1, for example. In thismanufacturing apparatus, plural conductive wires 1 arranged in parallelon the same plane are put between first insulating tape 2 and secondinsulating tape 3 while drawing them into portion between a pair ofheating rolls 4 along with the first and second insulating tapes to heatand pressure-fit the first and second insulating tapes 2 and 3 by thepair of beating rolls 4.

At the first and second insulating tapes 2 and 3, adhesive or bondinglayers are respectively formed on principal surfaces of the sidesopposite to each other. Further, in this manufacturing apparatus, priorto delivering or sending the first and second insulating tapes 2 and 3into the portion between the pair of heating rolls 4, first peeling orseparation sheets 5 are continuously stuck with a predetermined stickinginterval A on the adhesive layers of the first insulating tape 2 andsecond peeling sheets 6 are continuously stuck with a predeterminedsticking interval B on the adhesive layers of the second insulating tape3. When the first and second insulating tapes 2 and 3 are passed througha pair of heating rolls 4 so that they are pressure-fitted, the firstand second peeling sheets 5 and 6 are opposed to each other.

Moreover, the first and second peeling sheets 5 and 6 are stuck in amanner respectively perpendicular to length direction of the first andsecond insulating tapes 2 and 3, and are stuck so that portions arerespectively protruded from one ends in the width direction of the firstand second insulating tapes 2 and 3.

In addition, in this manufacturing apparatus, cut portions arerespectively formed along the outer shapes of the first peeling sheet 5and the second peeling sheet 6 by means of press cutter (not shown) atthe first and second insulating tapes 2 and 3. Thus, after the first andsecond insulating tapes 2 and 3 are heated and pressure-fitted,respective portions of the first and second insulating tapes 2 and 3 canbe peeled off together with the first and second peeling sheets 5 and 6.

Accordingly, the conductive wires 1 are exposed towards the externalfrom peeled off portions of the first and second insulating tapes 2 and3. Further, the conductive wires 1 are cut off at the exposed portions.There is thus manufactured flat cable in which plural conductive wires 1are coated with the first and second insulating tapes 2 and 3 and theconductive wires 1 are exposed from the both end portions.

Meanwhile, in manufacturing such flat cable, as shown in FIG. 2, it isrequired that first peeling sheet 5 stuck (attached) on the firstinsulating tape 2 and the second peeling sheet 6 stuck (attached) on thesecond insulating tape 3 are precisely opposite to each other when theyare passed through the portion between a pair of heating rolls 4.

For this reason, in the manufacturing apparatus, as shown in FIG. 1,first tape roll 7 a for supplying first insulating tape 2 and secondtape roll 7 b for supplying the second insulating tape 3 are disposed atpositions respectively equal in distance from the pair of heating rolls4. In addition, in this manufacturing apparatus, first sticking machine8 a for sticking first peeling sheets 5 and second sticking machine 8 bfor sticking second peeling sheets 6 are disposed at positionsrespectively equal in distance from the pair of heating rolls 4, andtimings for sticking these first and second peeling sheets 5 and 6 aresynchronized.

However, in such conventional manufacturing apparatus, e.g., in suchcases of intermittent sending out for sending out in succession firstand second insulating tapes 2 and 3, tensions applied to the first andsecond insulating tapes 2 and 3 are slightly changed (fluctuated) at thetime of start of sending out or at the time of stop. For this reason, inthe conventional manufacturing apparatus, there were instances where, asshown in FIG. 3, expansions/contractions of the first and secondinsulating tapes 2 and 3 change, whereby the first and second peelingsheets 5 and 6 are not precisely opposed to each other so thatpositional shift may take place.

Further, in the conventional manufacturing apparatus, when the firstinsulating tape 2 and the second insulating tape 3 are heated andpressure-fitted by a pair of heating rolls 4, adhesive layers formed onthe first and second insulating tape 2 and 3 are thermally contracted.For this reason, in the conventional manufacturing apparatus, theremight take place error in length of sticking (attachment) interval A offirst peeling sheets 5 disposed with a predetermined interval andsticking (attachment) interval B of second peeling sheets 6 disposedwith a predetermined interval.

As stated above, in the conventional manufacturing apparatuses, it wasdifficult to precisely oppose the first peeling sheet 5 and the secondpeeling sheet 6 for various causes. For this reason, with theconventional manufacturing apparatuses, there was the problem that it isdifficult to manufacture high quality flat cables.

In addition, in the conventional manufacturing apparatus, in the casewhere such sticking (attachment) error takes place in the first andsecond peeling sheets 5 and 6, it was necessary for correcting suchsticking error to once stop the apparatus and adjust it. However, thefact that the apparatus is allowed to be stopped results in cause tolower productivity to much degree.

DISCLOSURE OF THE INVENTION

This invention has been proposed in view of conventional circumstancesas described above, and its object is to provide a manufacturingapparatus and a manufacturing method for flat cable adapted formanufacturing high quality flat cables and having greatly improvedproductivity.

The manufacturing apparatus for flat cable according to this inventionwhich aims at attaining such object is directed to a manufacturingapparatus for flat cable in which plural conductive wires arranged onthe same plane are put between a first insulating tape on which firstpeeling sheets are stuck at predetermined intervals and a secondinsulating tape on which second peeling sheets are stuck atpredetermined intervals to stick the first insulating tape, theconductive wires and the second insulating tape in order recited, theapparatus comprising first tension applying means and second tensionapplying means for respectively applying predetermined tensions to thefirst insulating tape and the second insulating tape, detecting meansfor detecting passing of the first peeling sheet and the second peelingsheet after the first insulating tape and the second insulating tape putthe conductive wires therebetween, and control means for calculatingsticking errors of the first peeling sheets and the second peelingsheets on the basis of detection results that the detecting means hasdetected, and for controlling the first tension applying means and thesecond tension applying means on the basis of the sticking errors,wherein the control means controls the first tension applying means andthe second tension applying means to thereby respectively adjusttensions of the first insulating tape and the second insulating tape.

In this manufacturing apparatus for flat cable, since the first tensionapplying means and the second tension applying means respectively adjusttensions of the first insulating tape and the second insulating tape,expansions/contractions of the first insulating tape and the secondinsulating tape can be respectively independently changed. Further,since the control means controls the first tension applying means andthe second tension applying means on the basis of sticking errors of thefirst peeling sheet and the second peeling sheet detected by detectingmeans, sticking intervals of the first peeling sheets and the secondpeeling sheets can be caused to undergo feedback control.

The manufacturing method for flat cable according to this inventionwhich aims at attaining the above-mentioned object is directed to amanufacturing method for flat cable in which plural conductive wiresarranged on the same plane are put between a first insulating tape onwhich first peeling sheets are stuck at predetermined intervals and asecond insulating tape on which second peeling sheets are stuck atpredetermined intervals to stick the first insulating tape, theconductive wires and the second insulating tape in order recited,wherein the conductive wires are caused to be put between the firstinsulating tape and the second insulating tape thereafter to detectpassing of the first peeling sheet and the second peeling sheet tocalculate sticking errors of the first peeling sheets and second peelingsheets on the basis of the detection results to respectively adjusttensions applied to the first insulating tape and the second insulatingtape on the basis of this sticking errors.

In this manufacturing method for flat cable, tensions applied to thefirst insulating tape and the second insulating tape are respectivelyadjusted, thereby making it possible to respectively independentlychange expansions/contractions of the first insulating tape and thesecond insulating tape. In addition, tensions applied to the firstinsulating tape and the second insulating tape are respectively adjustedon the basis of the detected sticking errors of the first peeling sheetsand the second peeling sheets, thereby making it possible to correctsticking errors of the first peeling sheets and the second peelingsheets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view for explaining the configuration ofconventional manufacturing apparatus for flat cable.

FIG. 2 is a view showing the state where first peeling sheet and secondpeeling sheet are opposite to each other.

FIG. 3 is a view showing the state where the first peeling sheet andsecond peeling sheet are caused to undergo positional shift.

FIG. 4 is a schematic view for explaining the configuration of amanufacturing apparatus for flat cable to which this invention isapplied.

FIG. 5 is a schematic view for explaining the configuration of brakeunit provided at the manufacturing apparatus for flat cable to whichthis invention is applied.

FIG. 6 is a flowchart for explaining feedback control.

FIG. 7 is a schematic perspective view showing another example of theconfiguration of the manufacturing apparatus for flat cable to whichthis invention is applied.

FIG. 8 is a schematic view for explaining the configuration of anothermanufacturing apparatus for flat cable to which this invention isapplied.

FIG. 9 is a view showing the state where first peeling sheet and secondpeeling sheet are stuck in the state positionally shifted at apredetermined interval.

BEST MODES FOR CARRYING OUT THE INVENTION

Best Modes for carrying out this invention will now be described indetail with reference to the attached drawings.

An example of a manufacturing apparatus for flat cable (hereinaftersimply referred to as manufacturing apparatus) to which this inventionis applied is shown in FIG. 4.

In the manufacturing apparatus 10 shown in FIG. 4, plural conductivewires 11 arranged in parallel on the same plane are caused to be putbetween a first insulating tape 13 and a second insulating tape 15 whiledrawing such conductive wires into portion between a pair of heatingrolls 16 along with the first insulating tape 13 on which first peelingor separation sheets 12 are stuck at predetermined intervals and thesecond insulating tape 15 on which second peeling sheets 14 are stuck atpredetermined intervals to heat and pressure-fit the first insulatingtape 13 and the second insulating tape 15 by the pair of heating rolls16.

As the conductive wire 11, there may be used substantially tape shapedmetallic material, such as, for example, copper, aluminum, nickel,stainless steel, etc. In addition, as conductive wire 11, there may beused copper wire where plating such as tin, nickel aluminum, solder,etc. is implemented on its surface. In this example, plural conductivewires 11 are delivered from supply reels (not shown) in the state wherethey are disposed substantially in parallel to each other atpredetermined intervals.

As the first insulating tape 13 and the second insulating tape 15, theremay be used resin material having insulating property, e.g.,polyethylene terephthalate, polyethylene naphthalate, polyimide,polycarbonate, polyphenylene sulphide, vinyl chloride, etc., and paperor the like, wherein such material has width greater than width ofplural conductive wires 11 disposed substantially in parallel.

Moreover, adhesive or bonding layers are respectively formed on oneprincipal surfaces of the first insulating tape 13 and the secondinsulating tape 15. This adhesive layer consists of adhesive agent,e.g., polyester system resin, epoxy system resin, nylon system resin oracrylic system resin, etc. Such adhesive layer may be formed by a methodin which adhesive agents molded so as to have film shape in advance aredisposed on the first insulating tape 13 and the second insulating tape15, or a method in which adhesive agents in the state of low viscosityare coated on the surfaces of the first insulating tape 13 and thesecond insulating tape 15 to mold them so as to have thin film shape.

The first insulating tape 13 and the second insulating tape 15 arerespectively wound on a first tape roll 17 and a second tape roll 18.The first tape roll 17 and the second tape roll 18 are respectivelysupported, as shown in FIG. 5, by a first rotational shaft 19 and asecond rotational shaft 20. In addition, a first brake unit 21 and asecond brake unit 22 are respectively provided at the first rotationalshaft 19 and the second rotational shaft 20.

The first peeling sheets 12 and the second peeling sheets 14 arerespectively stuck, as shown in FIG. 4, by a first sticking machine 23and a second sticking machine employed sheet materials which have nocompatibility with the above-described adhesive agents. For example,arbitrary material such as paper, metallic foil or resion material, etc.may be used.

A pair of heating rolls 16 exhibit substantially columnar shape, whereinthe widths thereof are caused to be slightly greater than widths of thefirst insulating tape 13 and the second insulating tape 15, and heatersare respectively disposed therewithin.

In this manufacturing apparatus 10, there is employed a configurationsuch that surfaces where adhesive layers are formed of the firstinsulating tape 13 and the second insulating tape 15 are oppositelydisposed to each other through plural conductive wires 11 disposedsubstantially in parallel on the same plane. Further, in themanufacturing apparatus 10, the first tape roll 17 and the second taperoll 18 are disposed at positions equal in distance from the pair ofheating rolls 16. Namely, in the manufacturing apparatus 10, as shown inFIG. 4, the first tape roll 17 and the second tape roll 18 are disposedat positions bilaterally symmetric with respect to the pair of theheating rolls 16.

Moreover, in the manufacturing apparatus 10, the first sticking machine23 is disposed between the first tape roll 17 and the pair of heatingrolls 16, and the second sticking machine 24 is disposed between thesecond tape roll 8 and the pair of heating rolls 16. The first stickingmachine 23 and the second sticking machine 24 are adapted so that theyare disposed at positions equal in distance from the pair of heatingrolls 16, and their timings for sticking first peeling sheets 12 andsecond peeling sheets 14 are synchronized with each other.

Further, in the manufacturing apparatus 10, there is provided presscutter (not shown) for respectively forming cut portions along externalshapes of the first peeling sheet 12 and the second peeling sheet 14with respect to the first insulating tape 13 on which the first peelingsheets 12 are stuck and the second insulating tape 15 on which thesecond peeling sheets 14 are stuck.

In this manufacturing apparatus 10, dancer rolls 25 are respectivelydisposed on travelling paths of the first and second insulating tapes 13and 15, and the first and second insulating tapes 13 and 15 are laidover these dancer rolls 25. These dancer rolls 25 exhibit substantiallycolumnar shape, wherein they have widths caused to be slightly greaterthan widths of the first insulating tape 13 and the second insulatingtape 15, and apply predetermined tensions to the first insulating tape13 and the second insulating tape 15. In more practical sense, thesedancer rolls 25 are caused to have a predetermined weight and aredisposed in the state weighted in a vertical direction. For this reason,the dancer rolls 25 thrust or force the first insulating tape 13 and thesecond insulating tape 15 in a vertical direction to apply predeterminedtensions thereto.

Thus, in the manufacturing apparatus 10, it can be prevented that thefirst and second insulating tapes 13, 15 which are travelling areloosened. It is to be noted that, in the manufacturing apparatus, theremay be employed the configuration in which dancer rolls 25 are providedsimilarly with respect to the conductive wires 11.

Moreover, the manufacturing apparatus 10 comprises a first sensor 26 fordetecting first peeling sheet 12 stuck on the first insulating tape 13,a second sensor 27 for detecting second peeling sheet 14 stuck on thesecond insulating tape 15, and control unit (not shown) for controllingfirst brake unit 21 and second brake unit 22.

These first and second sensors 26 and 27 are disposed so that they arepositioned at succeeding stage of travelling direction of the firstinsulating tape 13 and the second insulating tape 15 with respect to thepair of heating rolls 16 and they are opposite to each other. The firstand second sensors 26 and 27 are not particularly limited totransmission type sensor, reflection type sensor, or camera, etc.

On the other hand, the control unit is of configuration in which it issupplied with signals from the first sensor 26 and the second sensor 27and it controls the first and second brake units 21 and 22 on the basisof control signal generated by the above-mentioned signal.

In the manufacturing apparatus 10, there are provided a pair of driverollers (not shown) positioned at the succeeding stage of travellingdirection of the conductive wires 11 and the first and second insulatingtapes 13 and 15 with respect to the first and second sensors 26 and 27.In the manufacturing apparatus 10, these pair of drive rollers aredriven so that the conductive wires 11, the first insulating tape 13 andthe second insulating tape 15 are drawn into the portion between a pairof heating rolls 16.

In the manufacturing apparatus 10 constituted as described above, firstand second insulating tapes 13 and 15 are respectively first suppliedfrom the first and second tape rolls 17 and 18, and are sent to a pairof heating rolls 16 side. Thus, before the first and second insulatingtapes 13 and 15 are sent into the portion between a pair of heatingrolls 16, first peeling sheets 12 are continuously stuck with apredetermined sticking interval C onto adhesive layers of the firstinsulating tape 13 and second peeling sheets 14 are continuously stuckwith a predetermined sticking interval D onto adhesive layers of thesecond insulating tape 15.

At this time, the first and second peeling sheets 12 and 14 are stuck ina manner respectively perpendicular to the length direction of the firstand second insulating tapes 13 and 15, and are stuck in such a mannerthat portions are protruded or projected from one end in the widthdirection of the first and second insulating tapes 13 and 15. Inaddition, there are respectively formed cut portions along the outershapes of the first and second peeling sheets 12 and 14 by press cutter(not shown) at the first and second insulating tapes 13 and 15.

Then, the first insulating tape 13 on which the first peeling sheets 12are stuck and the second insulating tape 15 on which second peelingsheets 14 are stuck are drawn into the portion between a pair of heatingrolls 16 in the state where plural conductive wires 11 are puttherebetween. At this time, as the result of the fact that the first andsecond insulating tapes 13 and 15 are heated and pressure-fitted by apair of heating rolls 16, the first insulating tape 13, the conductivewires 11 and the second insulating tape 15 are stuck in order recited.In addition, the first peeling sheet 12 and the second peling sheet 14are opposed to each other through conductive wires 11.

Then, the first and second insulating tapes 13 and 15 stuck through theconductive wires 11 are passed through the portion between the first andsecond sensors 26 and 27. At this time, the first sensor 26 detects theposition of the first peeling sheet 12 stuck on the first insulatingtape 13 and the second sensor 27 detects the position of the secondpeeling sheet 14 stuck on the second insulating tape 15. Further,position of the first peeling sheet 12 and position of the secondpeeling sheet 14 that the first and second sensors 26 and 27 haverespectively detected are sent to the control unit as detection signals.

At the control unit, sticking errors of the first and second peelingsheets are calculated on the basis of detection signals delivered fromthe first and second sensors 26 and 27. In the case where sticking errortakes place, a control signal is sent from the control unit to controlthe first or second brake unit 21 or 22.

In more practical sense, the control unit calculates sticking intervalC₁ of the first peeling sheets 12 on the first insulating tape 13, andcalculates sticking interval D₁ of the second peeling sheets 14 on thesecond insulating tape 15. Further, the control unit controls the firstand second brake units 21 and 22 on the basis of the calculationresults, thereby allowing sticking interval C of the first peelingsheets 12 and sticking interval D of the second peeling sheets 14 to bedesired lengths, respectively.

In this case; the first and second brake units 21 and 22 are adapted sothat when their braking forces are strengthened (enhanced) by controlsignal from the control unit, they strengthen (enhance) tension appliedto the first and second insulating tapes 13 and 15. Thus, when tensionsapplied to the first and second insulating tapes 13 and 15 arestrengthened, the first and second insulating tapes 13 and 15 areexpanded. Accordingly, by strengthening (enhancing) braking forces ofthese first and second brake units 21 and 22, sticking interval C andsticking interval D can be enlarged.

On the contrary, the first and second brake units 21 and 22 are adaptedso that when their braking forces are weakened by control signal fromthe control unit, they weaken tensions applied to the first and secondinsulating tapes 13 and 15. Thus, when tensions applied to the first andsecond insulating tapes 13 and 15 are weakened, these first and secondinsulating tapes 13 and 15 are contracted. Accordingly, by weakeningbraking forces of these first and second brake units 21 and 22, stickinginterval C and sticking interval D can be reduced.

As stated above, such an approach is employed to respectivelyindependently control relative expansions/contractions of the first andsecond insulating tapes 13 and 15, thereby permitting sticking intervalC of the first peeling sheets 12 and sticking interval D of the secondpeeling sheets 14 to be desired lengths, respectively. Further, in thismanufacturing apparatus 10, there can be carried out such a feedbackcontrol to adjust sticking interval C and sticking interval D on thebasis of detection signals from the first and second sensors 26 and 27.

A more practical flowchart of such a feedback control is shown in FIG.6.

In carrying out such feedback control, at step S1, positions of thefirst and second peeling sheets 12 and 14 are first detected. Theprocessing proceeds to step S2.

At the step S2, positional shift between the first and second peelingsheets 12 and 14 is discriminated on the basis of the detection resultsat the step S1. Namely, in the case where sticking error takes placebetween the first peeling sheet 12 and the second peeling sheet 14, theprocessing proceeds to step S3. On the other hand, in the case where thefirst peeling sheet 12 and the second peeling sheet 14 are preciselyopposite to each other, the processing returns to the step S1. Thus, theprocessing are repeated for a second time.

At the step S3, a procedure is taken to calculate sticking interval C₁of the first peeling sheets 12 and sticking interval D₁ of the secondpeeling sheets 14 to compare them with standard length to therebydiscriminate any one of which sticking interval C₁ and sticking intervalD₁ is different from the standard length. As the result ofdiscrimination, in the case where the first peling sheet 12 ispositionally shifted with respect to the standard length, the processingproceeds to step S4. In the case where the second peeling sheet 14 ispositionally shifted with respect to the standard length, the processingproceeds to step S5.

At the step S4, whether the sticking interval C₁ of the first peelingsheet 12 is longer or shorter than the standard length is discriminated.In the case where the sticking interval C₁ is long with respect to thestandard length, the processing proceeds to step S6-1. On the otherhand, in the case where the sticking interval C₁ is short with respectto the standard length, the processing proceeds to step S6-2.

At the step S6-1, the first brake unit 21 is controlled to weakenbraking force. Thus, a correction is made such that expansion of thefirst insulating tape 13 is reduced and the sticking interval C of thefirst peeling sheet 12 is shortened. Further, the processing returns tothe step S1 to repeat processing for a second time.

At the step S6-2, the first brake unit 21 is controlled to strengthen orenhance braking force. Thus, a correction is made such that expansion ofthe first insulating tape 13 is enlarged and sticking interval C of thefirst peeling sheet 12 is elongated. Further, the processing returns tothe step S1 to repeat the processing for a second time.

On the other hand, at step S5, whether the sticking interval D₁ of thesecond peeling sheet 14 is long or short with respect to the standardlength is discriminated. In the case where the sticking interval D₁ islong with respect to the standard length, the processing proceeds tostep S7-1. In the case where sticking interval D₁ is short with respectto the standard length, the processing proceeds to step S7-2.

At the step S7-1, the second brake unit 22 is controlled to weakenbraking force. Thus, a correction is made such that expansion of thesecond insulating tape 15 is reduced and the sticking interval D of thesecond peeling sheets 14 is shortened. Further, the processing returnsto the step S1 to repeat the processing for a second time.

At the step S7-2, the second brake unit 22 is controlled to strengthenor enhance braking force. Thus, a correction is made such that expansionof the second insulating tape 15 is enlarged and the sticking distance Dof the second peeling sheets 14 is elongated. Further, the processingreturns to the step S1 to repeat the processing for a second time.

As stated above, in the manufacturing apparatus 10, by repeatingprocessing in accordance with such a feedback control, correction can bemade such that sticking interval C of the first peeling sheets 12 andsticking interval D of the second peeling sheets 14 are allowed to berespectively desired lengths. Accordingly, in this manufacturingapparatus 10, it is possible to precisely oppose the first peeling sheet12 and the second peeling sheet 14.

Then, the first peeling sheet 12 and the second peeling sheet 14 arepeeled off from the first insulating tape 13 and the second insulatingtape 15 which have been stuck through the conductive wires 11. In thisexample, at the first and second insulating tapes 13 and 15, there arerespectively formed cut portions along outer shapes of the first andsecond peeling sheets 12 and 14. Thus, it is possible to easily peel offportions of the first and second insulating tapes 13 and 15 along withthe first and second peeling sheets 12 and 14.

Accordingly, it is possible to expose conductive wires 11 at equalintervals from the both surfaces of the first and second insulatingtapes 13 and 15. Further, by cutting conductive wires 11 exposed fromthe both surfaces of the first and second insulating tapes 13 and 15 toallow them to have a predetermined length, it is possible to manufactureflat cable in which conductive wires 11 are exposed from the both endportions in its length direction.

As stated above, in the manufacturing apparatus 10, the first brake unit21 and the second brake unit 22 respectively adjust tensions of thefirst insulating tape 13 and the second insulating tape 15, therebymaking it possible to respectively independently changeexpansions/contractions of the first and second insulating tapes 13 and15. In addition, in this manufacturing apapratus 10, it is possible tocarry out feedback control of sticking interval C of the first peelingsheets 12 and sticking interval D of the second peeling sheets 14.

For this reason, in the manufacturing apparatus 10, it is possible toprecisely oppose the first peeling sheet 12 and the second peeling sheet14. Thus, it is possible to prevent positional shift of conductive wires11 exposed from the both surfaces of the first insulating tape 13 andthe second insulating tape 15. In other words, at the portions fromwhich conductive wires 11 are exposed of the flat cable, end surface ofthe first insulating tape 13 and end surface of the second insulatingtape 15 are permitted to be flush with each other.

In addition, in the manufacturing apparatus 10, since such a feedbackcontrol is carried out, it is unnecessary for correcting sticking errorbetween the first peeling sheet 12 and the second peeling sheet 14 toonce stop the apparatus to adjust it.

Accordingly, in this manufacturing apparatus 10, it is possible togreatly improve productivity of flat cables. Thus, high quality flatcables in which product yield has been improved can be manufactured.

It is to be noted that, in the manufacturing apparatus 10, as shown inFIG. 4, there is employed the configuration in which first tape roll 17and second tape roll 18 are arranged in horizontal direction withrespect to vertical direction, and dancer rolls 25 are respectivelydisposed on travelling paths of the first and second insulating tapes 13and 15. However, the manufacturing apparatus for flat cable to whichthis invention is applied is not limited to such a configuration. Forexample, there may be employed a configuration such that first tape roll17 and second tape roll 18 are arranged in vertical direction throughconductive wires 11 as shown in FIG. 7.

In this case, it is unnecessary to dispose dancer rolls 25 for carryingout weighting in vertical direction, thus permitting the entirety of theapparatus to become more compact.

Moreover, as in the manufacturing apparatus shown in FIG. 7, there maybe employed a configuration using first tape roll 17 where there iswound first insulating tape 13 on which first peeling sheets 12 arestuck at predetermined intervals and second tape roll 18 where there iswound second insulating tape 15 on which second peeling sheets 14 arestuck at predetermined intervals.

In this case, it is unnecessary to provide the above-described first andsecond sticking machines 23 and 24. Thus, the entirety of the apparatuscan become more compact.

In addition, in the manufacturing apparatus 10, there is employed theconfiguration in which the first and second peeling sheets 12 and 14 arestuck with respect to the first and second insulating tapes 13 and 15 inthe state where such peeling sheets are opposite to each other. However,the manufacturing apparatus for flat cable to which this invention isapplied is not limited to such a configuration. For example, there maybe employed a configuration such that the first and second peelingsheets 12 and 14 are stuck in the state positionally shifted to eachother at a predetermined interval.

Another manufacturing apparatus for flat cable to which this inventionis applied is shown in FIG. 8. It is to be noted that, in FIG. 8,explanation will be omitted with respect to portions equivalent to theabove-described manufacturing apparatus 10, and the same referencenumerals are respectively attached thereto.

The manufacturing apparatus 30 shown in FIG. 8 is directed to amanufacturing apparatus for flat cable in which first peeling sheets 12and second peeling sheets 14 are respectively stuck onto firstinsulating tape 13 and second insulating tape 15 in the state where suchpeeling sheets are positionally shifted to each other at a predeterminedinterval.

This manufacturing apparatus 30 comprises feed reel (not shown) fordelivering plural conductive wires 11, a first tape roll 17 and a secondtape roll 18 for respectively delivering first insulating tape 13 andsecond insulating tape 15, a pair of heating rolls 16 for allowingplural conductive wires 11 to be put therebetween along with firstinsulating tape 13 and second insulating tape 15, and a pair of driverollers 31 for drawing thereinto these conductive wires 11 and the firstand the second insulating tapes 13 and 15.

Moreover, in this manufacturing apparatus 30, dancer rolls 25 arerespectively disposed on travelling paths of the conductive wires 11,and the first and second insulating tapes 13 and 15, and the conductivewires 11, and the first and second insulating tapes 13 and 15 are laidover these dancer rolls 25. In addition, this manufacturing apparatus 30comprises first sticking machine, second sticking machine and presscutter which are not shown.

Further, in this manufacturing apparatus 30, in place of theabove-described first and second brake units 21 and 22, a brake roll 32for applying a predetermined tension to the first insulating tape 13 isdisposed on travelling path of the first insulating tape 13, and is laidover the first insulating tape 13. This brake roll 32 can be moved in adirection substantially perpendicular to the direction in which tensionis applied to the first insulating tape 13.

In addition, this manufacturing apparatus 30 comprises control unit (notshown) for calculating sticking errors of the first and second peelingsheets 12 and 14 and for controlling the brake roll 32.

In the manufacturing apparatus 30 thus constituted, as shown in FIG. 9,the first sensor 26 and the second sensor 27 respectively detectpositions of the first peeling sheet 12 and the second peeling sheet 14.Further, position of the first peeling sheet 12 and position of thesecond peeling sheet 14 that the first sensor 26 and the second sensor27 have detected are respectively sent out to the control unit asdetection signals.

In the control unit, there are calculated sticking errors of the firstpeeling sheet 12 and the second peeling sheet 14 on the basis ofdetection signals received from the first sensor 26 and the secondsensor 27. Further, in the case where any sticking error takes place,control signal is sent from the control unit to control the brake roll32.

In this case, as shown in FIG. 9, output from the control unit to thebrake roll 32 is expressed as follows.Output=(Y−(X+Y)/2)×KIn the above-mentioned formula, X indicates sticking interval betweenthe first peeling sheet 12 a and the second peeling sheet 14 a, Yindicates sticking interval between the second peeling sheet 14 a andthe next peeling sheet 12 b, and K indicates coefficient correspondingto material used in the first and second insulating tapes 13 and 15.

The brake roll 32 moves in a direction substantially perpendicular tothe direction in which tension is applied to the first insulating tape13 in accordance with an output from this control unit. Thus, the brakeroll 32 can adjust tension applied to the first insulating tape 13 andcan change expansion/contraction of the first insulating tape 13.

In more practical sense, in the case where sticking interval between thefirst peeling sheet 12 and the second peeling sheet 14 is short, thebrake roll 32 moves in a direction away from the first insulating tape13 indicated by arrow E in FIG. 8 to thereby strengthen or enhancetension applied to the first insulating tape 13. Further, when tensionapplied to the first insulating tape 13 is strengthened, this firstinsulating tape 13 is expanded. Thus, sticking interval between thefirst and second peeling sheets 12 and 14 can be enlarged.

On the contrary, in the case where sticking interval between the firstand second peeling sheets 12 and 14 is long, the brake roll 32 moves ina direction close to the first insulating tape 13 indicated by arrow Fin FIG. 8 to thereby weaken tension applied to the first insulating tape13. Further, when the tension applied to the first insulating tape 13 isweakened, this first insulating tape 13 is contracted. Thus, stickinginterval between the first peeling sheet 12 and the second peeling sheet14 can be reduced.

As stated above, in the manufacturing apparatus 30, by controlling thebrake roll 32, sticking interval between the first peeling sheet 12 andthe second peeling sheet 14 is permitted to be desired length. Further,in this manufacturing apparatus 30, it is possible to carry out such afeedback control to adjust sticking interval between the first peelingsheet 12 and the second peeling sheet 14 on the basis of detectionsignals from the first sensor and the second sensor 26 and 27.

The manufacturing apparatus 30 repeats the processing in accordance withsuch a feedback control, thereby making it possible to make a correctionsuch that sticking interval between the first and second peeling sheets12 and 14 is caused to be desired length. Accordingly, in thismanufacturing apparatus 30, it is possible to precisely stick the firstpeeling sheet 12 and the second peeling sheet 14 in the statepositionally shifted at a predetermined interval.

Then, the first peeling sheet 12 and the second peeling sheet 14 arepeeled off from the first insulating tape 13 and the second insulatingtape 15 which have been stuck through the conductive wires 11. Thus,there is manufactured a flat cable in which conductive wires 11 arealternately exposed at predetermined intervals from both surfaces of thefirst insulating tape 13 and the second insulating tape 15.

As stated above, in the manufacturing apparatus 30, the brake roll 32respectively adjusts tension of the first insulating tape 13, therebymaking it possible to change expansion/contraction of the firstinsulating tape 13. Further, in this manufacturing apparatus 30, it ispossible to carry out feedback control of sticking interval of the firstpeeling sheets 12 and sticking interval of the second peeling sheets 14.

For this reason, in the manufacturing apparatus 30, it is possible toprecisely stick the first peeling sheet 12 and the second peeling sheet14 in the state positionally shifted as a predetermined intervals. Thus,it is possible to manufacture flat cable in which conductive wires 11are alternately exposed precisely at predetermined intervals from bothsurfaces of the first insulating tape 13 and the second insulating tape15.

In addition, in the manufacturing apparatus 30, since such a feedbackcontrol is carried out, it is unnecessary for correcting sticking errorbetween the first peeling sheet 12 and the second peeling sheet 14 toonce stop the apparatus to adjust it. Accordingly, this manufacturingapparatus 30 can greatly improve productivity of flat cables. Thus, highquality flat cables in which product yield has been improved can bemanufactured.

INDUSTRIAL APPLICABILITY

In the manufacturing apparatus for flat cable according to thisinvention, since the first tension applying means and the second tensionapplying means respectively adjust tensions of the first and secondinsulating tapes, it is possible to respectively independently changeexpansions/contractions of the first and second insulating tapes.Further, the control means controls the first tension applying means andthe second tension applying means on the basis of sticking errors of thefirst peeling sheets and the second peeling sheets which are detected bythe detecting means, thereby making it possible to carry out feedbackcontrol of sticking intervals of the first peeling sheets and the secondpeeling sheets.

Accordingly, in accordance with this manufacturing apparatus, it isunnecessary for correcting sticking error between first peeling sheetand second peeling sheet to once stop the apparatus to adjust it. As aresult, productivity of flat cable can be greatly improved. Thus, highquality flat cables in which product yield has been improved can bemanufactured.

Further, in the manufacturing method for flat cable according to thisinvention, a procedure is taken to respectively adjust tensions appliedto the first and second insulating tapes, thereby making it possible torespectively independently change expansions/contractions of the firstand second insulating tapes. A further procedure is taken torespectively adjust tensions applied to the first and second insulatingtapes on the basis of detected sticking errors of the first and secondpeeling sheets, thereby making it possible to correct sticking errors ofthe first and second peeling sheets.

Accordingly, in accordance with this technique, since first peelingsheets and second peeling sheets are respectively precisely stuck(attached) at predetermined intervals onto the first insulating tape andthe second insulating tape, productivity of flat cable can be greatlyimproved. Thus, high quality flat cable in which product yield has beenimproved can be manufactured.

1. An apparatus for manufacturing flat cable in which plural conductivewires arranged on the same plane are put between a first insulating tapeon which first peeling sheets are stuck at predetermined intervals and asecond insulating tape on which second peeling sheets are stuck atpredetermined intervals to stick the first insulating tape, theconductive wires and the second insulating tape in order recited, theapparatus comprising: first tension applying means and second tensionapplying means for respectively applying predetermined tensions to thefirst insulating tape and the second insulating tape; detecting meansfor allowing the conductive wires to be put between the first insulatingtape and the second insulating tape thereafter to detect passing of thefirst peeling sheet and the second peeling sheet; and control means forcalculating sticking errors of the first peeling sheets and the secondpeeling sheets on the basis of detection results that the detectingmeans have detected, and for controlling the first tension applyingmeans and second tension applying means on the basis of these stickingerrors, wherein the control means controls the first tension applyingmeans and the second tension applying means to thereby respectivelyadjust tensions of the first insulating tape and the second insulatingtape.
 2. The apparatus for manufacturing flat cable as set forth inclaim 1, wherein the first insulating tape and the second insulatingtape are respectively wound on tape rolls, and wherein the first tensionapplying means and the second tension applying means are rotationalcontrol means for controlling rotational drive of the tape rolls.
 3. Theapparatus for manufacturing flat cable as set forth in claim 1, whereinthe first tension applying means and the second tension applying meansare brake rolls disposed on travelling paths of the first insulatingtape and the second insulating tape.
 4. The apparatus for manufacturingflat cable as set forth in claim 1, wherein the first insulating tapeand the second insulating tape are stuck through the conductive wires insuch a manner to oppose the first peeling sheet and the second peelingsheet.
 5. The apparatus for manufacturing flat cable as set forth inclaim 1, wherein the first insulating tape and the second insulatingtape are stuck through the conductive wires in such a manner that thefirst peeling sheets and the second peeling sheets are positionallyshifted at predetermined intervals.
 6. The apparatus for manufacturingflat cable as set forth in claim 1, which includes dancer rolls forrespectively applying predetermined tensions to the first insulatingtape and the second insulating tape.
 7. A method for manufacturing flatcable in which plural conductive wires arranged on the same plane areput between a first insulating tape on which first peeling sheets arestuck at predetermined intervals and a second insulating tape on whichsecond peeling sheets are stuck at predetermined intervals to stick thefirst insulating tape, the conductive wires and the second insulatingtape in order recited, the method comprising the steps of: allowing theconductive wires to be put between the first insulating tape and thesecond insulating tape thereafter to detect passing of the first peelingsheet and the second peeling sheet; calculating sticking errors of thefirst peeling sheets and the second peeling sheets on the basis of thedetection results; and respectively adjusting tensions applied to thefirst insulating tape and the second insulating tape on the basis of thesticking errors.
 8. The method for manufacturing flat cable as set forthin claim 7, wherein the first insulating tape and the second insulatingtape are stuck through the conductive wires so as to oppose the firstpeeling sheet and the second peeling sheet.
 9. The method formanufacturing flat cable as set forth in claim 7, wherein the firstinsulating tape and the second insulating tape are stuck through theconductive wires in such a manner that the first peeling sheet and thesecond peeling sheet are positionally shifted at predeterminedintervals.